How an Industrial Service Provider Modernized Their Filtration Systems with RAKwireless IoT and LoRaWAN
| Quick Look Use Case Summary | |
|---|---|
| Principal Emphasis | RAKwireless Product Value |
| Industry | Smart Industries |
| Sub-Industry | Industrial Operations |
| Deployment Area | Industrial, Factory Potential, Large-scale Industrial Sites |
| Deployment Scale | Enterprise |
| IoT Product(s) Used | Pressure sensors with RAK3172 modules, RAK7268V2 Gateways, AWS IoT Core for LoRaWAN, and a custom dashboard |
Highlights
A UK-based air filtration company transformed its outdated, manual service model into a smart, data-driven system using RAKwireless and LoRaWAN. By integrating real-time pressure sensors, long-range gateways, and a custom dashboard, they eliminated unnecessary site visits, reduced costs, and improved maintenance accuracy. The system now runs across 30+ sites with 400+ devices. After proven success, the company is expanding to Germany, Australia, and the US, scaling with global-ready RAK modules.
Business Introduction
In the world of industrial maintenance, you don’t usually hear “simple”, “smart”, and “low-cost” in the same sentence. But one UK-based industrial company actually pulled it off. They teamed up with the right engineering partner, used LoRaWAN, and chose RAKwireless to power it all.
This wasn’t just a small upgrade. They started as a regular air filtration business with an old-school service model. However, they successfully flipped the script and now run a scalable system that’s smart and works with real-time data. Better yet, their journey has just begun.
The Problems They Couldn’t Ignore Anymore
Imagine running a service business across the country where your technicians drive hundreds of miles each month just to check if an air filter might need changing. That’s exactly what this UK-based company was doing. They specialized in maintaining industrial air filtration systems. Their job was to install, service, and replace panel filters in factories all over the UK.
However, there was one big problem. They had no way of knowing if a filter actually needed changing until someone showed up in person to check it. There were no sensors, no alerts, and no data to rely on. So what did that mean for the business?
Here’s what their service model looked like at the time:
| Challenge | How Does it Affect Operations? |
|---|---|
| No way to remotely check filter condition | Technicians had to visit each site in person |
| Routine service visits | Trips were made even when the filters were clean |
| High travel and labor costs | More fuel, more hours, more wear on the team |
| Premature replacements | Filters were thrown out before it was required |
| No real-time system visibility | No data to help plan maintenance or catch trouble |
It wasn’t just inefficient, it was expensive and slowed them down. Also, it made it harder to scale or meet the fast-changing client expectations. They knew there had to be a better way!
The Turning Point
In 2021, they approached Innovisory, a UK-based IoT engineering firm, with a simple question: Can we build a system that tells us when a filter really needs to be changed—before it becomes a problem?
Innovisory said yes! In fact, they were ready with a smart and practical solution that could transform the entire service model. They explored different hardware options to compare features, performance, and long-term reliability. After careful testing and review, they made a confident choice and picked RAKwireless to power the new system. This partnership marked the beginning of something big.
The Smart Setup: LoRaWAN, RAK, AWS, and a Live Dashboard
Innovisory’s team began with a hands-on approach. They built a working prototype using a few development boards, some pressure sensors, and a basic PCB. This early version helped them test the idea in real settings. Once the pilot showed strong results, they didn’t stop there. They moved forward with confidence and turned the design into a reliable production-ready system.
Here’s what they built, step by step:
| Component | What is it? | What Does it Do? | Why It Matters? |
|---|---|---|---|
| Smart Sensor Node | Based on the RAK3172 WisDuo module. | Supports up to 3 differential pressure sensors and shows live data on an LCD screen. | Allows technicians to read filter status on-site without needing extra equipment. |
| RAK7268V2 Gateways | Installed in factories across the UK. | Uses LTE or Ethernet to send sensor data to the cloud. | Ensures a reliable connection across multiple factory locations. |
| AWS IoT Core for LoRaWAN | The cloud backend that powers communication. | Fully connected to a custom-built dashboard. | Stores, processes, and displays data while enabling real-time alerts and remote configuration. |
| Custom Dashboard | Web interface integrated with AWS backend. | Let's teams visualize filter health, get alerts, and change settings remotely. | Helps reduce on-site visits and gives full visibility into system performance. |
| Ultra-Low Power Nodes | Built with energy efficient design. | Each node can run on battery for up to 4 years. | Saves time and cost on battery changes while keeping the system dependable in remote areas. |
This was a carefully planned setup where everything had a clear job to do. Each part was specially designed to fix a real problem. It all worked together as one smooth system. Nothing felt extra or out of place. It was simple, solid, and built to make daily operations easier from the very start.
The Results From Reactive to Predictive Maintenance
Fast forward to today, and the system is now live at over 30 industrial sites across the UK. More than 400 smart sensor nodes are working nonstop to monitor air filters in real time. The results have been clear and impressive.
Here are the tangible benefits they gained from this transformation:
- Real-time visibility of air systems across all locations.
- Automated fault alerts before issues escalate
- Reduced field service costs by cutting unnecessary visits.
- Less waste by replacing filters only when truly needed.
- Increased client satisfaction through our proactive service.
- Auto-generated reports for clients via the dashboard.
Why RAKwireless? Here's What Made the Difference
Innovisory took their time exploring different hardware options before making a final decision. After careful testing and evaluation, they chose RAK—because it checked every box that mattered for both the pilot and the long-term rollout.
Here’s why RAKwireless stood out from the rest:
| Reason | Value |
|---|---|
| Affordability | The RAK3172 met cost targets for both prototyping and scale |
| Ease of Integration | Extra GPIO, UART, and I2C allowed for a single-chip design—no external MCU required |
| Ultra-Low Power | Sub-1μA sleep current enabled multi-year battery life |
| Global Certification | CE, FCC, AU/NZ type approvals made global deployment easier |
| Responsive Support | RAK helped fine-tune gateway firmware for better downlink performance and lower power use |
We’ve built and deployed over 400 devices using RAK modules. They’ve been running non-stop for over 18 months—without a single failure.
— Innovisory Engineering Lead
What’s Next? Expansion to Europe, Australia, and the US
With solid results and proven performance across more than 30 industrial sites in the UK, the team at Innovisory is now preparing to take their solution global. Their expansion plans are already underway, and each region brings its own opportunities and technical requirements.
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🇩🇪 Germany:
Germany is the first step in their European rollout. With CE certification already in place, they’re positioned to deploy quickly and meet local regulatory standards without delay. This makes it easier to move confidently into new EU markets where compliance is non-negotiable. -
🇦🇺 Australia & New Zealand:
Next on the roadmap is Australia and New Zealand. The team is currently working through local certification requirements using RAK’s AU915-compatible modules. These modules are tailored to meet the radio frequency standards in that region, allowing the same solution to function seamlessly without the need for a complete redesign. -
🇺🇸 USA:
Looking further ahead, they’re setting their sights on North America. Plans are in motion to launch a US915 version of the system to support industrial customers across the United States. This means customizing the hardware to meet the LoRaWAN specifications unique to the US, while still maintaining the same smart, efficient backbone.
Through each phase of expansion, the RAK module remains at the core of the product. Our flexibility across frequency bands, consistent reliability, and global compliance make us the ideal hardware for scaling across borders.
A Blueprint for Industrial IoT Innovation
This success story shows that innovation doesn’t require reinventing the wheel. Big results follow when a traditional industrial business partners with the right team and uses the right technology. That’s exactly what happened here. What began as a manual, labor-intensive service model evolved into a high-tech and data-driven operation that’s easier to manage, scale, and is more valuable to customers.
They have truly changed how their team works and the experience their clients receive. All this became possible by smartly combining pressure sensors, real-time cloud dashboards, and smart devices that work for years without maintenance.
It all started with a simple question:
Can we stop guessing and start knowing?
And with RAKwireless and LoRaWAN at the foundation, that question turned into a fully deployed solution that now powers a growing and modern business.
Getting Started
Want to learn more about how RAKwireless can support your next industrial IoT deployment? Contact us today, we’d love to help you build what’s next.